Ribbed tubeless heat exchanger for fluid heating systems including a rib component and methods of manufacture thereof

ABSTRACT

A tubeless heat exchanger for heating a production fluid disposed in a vessel, including: a tubeless heat exchanger core disposed at least partially within the vessel, the tubeless heat exchanger core comprising an inner casing and an outer casing disposed around the inner casing, the inner and outer casings defining therebetween a flow passage for a thermal transfer fluid to flow, the tubeless heat exchanger core further comprising a core inlet arranged to receive the thermal transfer fluid and a core outlet arranged to provide the thermal transfer fluid, the core inlet and core outlet being fluidically connected to the flow passage, wherein each of the outer casing and the inner casing has an inner surface and an outer surface, wherein the respective inner surfaces face each other and define therebetween the flow passage for the thermal transfer fluid to flow and wherein at least a portion of the respective outer surfaces are arranged to be contacted by the production fluid, wherein the flow passage defines a path comprising at least one pass around a perimeter of the heat exchanger core, and wherein, in use, the thermal transfer fluid in the heat exchanger core transfers heat from the thermal transfer fluid to the production fluid through at least a portion of both the inner and outer casings.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. provisional patent application Ser. No. 62/124,235, filed on Dec. 11, 2014, the content of which is included herein by reference in its entirety.

BACKGROUND Field of the Disclosure

This application relates to a tubeless heat exchanger for a fluid heating system, methods of manufacture of the tubeless heat exchanger, and fluid heating systems including the tubeless heat exchanger.

Description of the Related Art

Heat exchangers are used in fluid heating systems to transfer heat from a thermal transfer fluid, such as a combustion gas produced by combustion of a fuel such as petroleum or natural gas, to a production fluid. The production fluid can then be used for a variety of commercial, industrial, or domestic applications such as hydronic, steam, and thermal fluid boilers, for example. Because of the desire for improved energy efficiency, compactness, and cost reduction, there remains a need for improved heat exchangers, and fluid heating systems including the same, as well as improved methods of manufacture thereof.

SUMMARY

Disclosed is a heat exchanger including: a heat exchanger core including a top head, a bottom head, a first casing disposed between the top head and the bottom head, a second casing disposed between the top head and the bottom head, wherein an inner surface of the first casing is opposite an inner surface of the second casing, an inlet on the first casing, the second casing, or combination thereof, an outlet on the first casing, the second casing, or combination thereof, and a rib disposed between the first casing and the second casing, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet; a pressure vessel; an inlet member on the inlet, which connects the inlet to an outside of the pressure vessel; and an outlet member on the outlet, which connects the outlet to an outside of the pressure vessel, wherein the bottom head, the first casing, and the second casing are contained entirely within the pressure vessel.

Also disclosed is a method of manufacturing a heat exchanger core, the method including: providing a first casing; disposing a rib on an inner surface of the first casing; providing a second casing including a slot; aligning the rib and the slot by disposing the first casing on the second casing; rigidly attaching the rib to the second casing; disposing a top head on a first end of each of the first casing and the second casing; disposing a bottom head on a second end of each of the first casing and the second casing; disposing an inlet on the first casing, the second casing, or a combination thereof; and disposing an outlet on the first casing, the second casing, or a combination thereof to manufacture the heat exchanger core, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet.

Also disclosed is a method of manufacturing a heat exchanger core, the method including: providing a first casing; disposing a second casing including a slot on the first casing; disposing a rib through the slot; rigidly attaching the rib to at least one of the first casing and the second casing; disposing a top head on an upper end of each of the first casing and the second casing; disposing a bottom head on a lower end of each of the first casing and the second casing; disposing an inlet on the first casing, the second casing, or a combination thereof; and disposing an outlet on the first casing, the second casing, or a combination thereof to manufacture the heat exchanger core, wherein the rib, the first casing, and the second casing define a flow passage between the inlet the outlet.

Also disclosed is a method of manufacturing a heat exchanger core, the method including: providing a first casing; disposing a rib on an inner surface of the first casing; disposing a second casing member on an outer surface of the first casing, wherein the inner surface of the first casing is opposite an inner surface of the second casing member; rigidly attaching longitudinal edges of the second casing member to form a second casing; disposing a top head on an upper end of each of the first casing and the second casing; disposing a bottom head on a lower end of each of the first casing and the second casing; disposing an inlet on the first casing, the second casing, or combination thereof; and disposing an outlet on the first casing, the second casing, or combination thereof to manufacture the heat exchanger core, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet.

Also disclosed is a method of manufacturing a heat exchanger core, the method including: providing a first casing and a second casing; disposing a rib on an inner surface of the first casing or on an inner surface of the second casing; heating or cooling at least one of the first casing and the second casing; disposing the second casing on the first casing; thermally equilibrating the first casing and the second casing to contact at least one of an inner surface of the first casing and the rib and an inner surface of the second casing and the rib; disposing a top head on an upper end of each of the first casing and the second casing; disposing a bottom head on a lower end of each of the first casing and the second casing; disposing an inlet on the first casing, the second casing, or combination thereof; disposing an outlet on the first casing, the second casing, or combination thereof to manufacture the heat exchanger core, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet.

A method of manufacturing a heat exchanger core, the method including: providing a first casing; disposing a rib on an inner surface of the first casing; disposing a second casing on the rib; deforming at least one of the first casing and the second casing to contact at least one of the first casing and the rib and the second casing and the rib; disposing a top head on an upper end of each of the first casing and the second casing; disposing a bottom head on a lower end of each of the first casing and the second casing; disposing an inlet on the first casing, the second casing, or combination thereof; and disposing an outlet on the first casing, the second casing, or combination thereof to manufacture the heat exchanger core, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet.

Also disclosed is a method of manufacturing a heat exchanger core, the method including: providing a first casing; disposing a tubular rib on an inner surface of the first casing; disposing the first casing on a second casing; expanding the rib to contact the expanded rib and the first casing and the expanded rib and the second casing; disposing a top head on an upper end of each of the first casing and the second casing; disposing a bottom head on a lower end of each of the first casing and the second casing; disposing an inlet on the first casing, the second casing, or combination thereof; and disposing an outlet on the first casing, the second casing, or combination thereof to manufacture the heat exchanger core, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet.

Also disclosed is a method of manufacturing a heat exchanger core, the method including: providing a first casing; disposing a rib on an inner surface of the first casing; providing a second casing, wherein an inner surface of the second casing includes a groove, which is configured to receive the rib; rotating the first casing relative to the second casing to thread the first casing into the second casing to dispose the first casing in or on the second casing; optionally expanding or contracting at least one of the first casing and the second casing so that the rib contacts the first casing and the second casing; disposing a top head on an upper end of each of the first casing and the second casing; disposing a bottom head on a lower end of each of the first casing and the second casing; disposing an inlet on the first casing, the second casing, or combination thereof; and disposing an outlet on the first casing, the second casing, or combination thereof to manufacture the heat exchanger core, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet.

Also disclosed is a method of manufacturing a heat exchanger core, the method including: providing a first casing; disposing a rib on an inner surface of the first casing; contacting the rib and an inner surface of a second casing by disposing the first casing on the outer casing; disposing a top head on an upper end of each of the first casing and the second casing; disposing a bottom head on a lower end of each of the first casing and the second casing; disposing an inlet on the first casing, the second casing, or combination thereof; and disposing an outlet on the first casing, the second casing, or combination thereof to manufacture the heat exchanger core, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet.

Also disclosed is a method of manufacturing a heat exchanger, the method including: providing a shell; disposing a pressure vessel bottom head on the shell; disposing the heat exchanger core of claim 1 in the shell; and disposing a pressure vessel top head on the shell to manufacture the heat exchanger, wherein the pressure vessel top head, the pressure vessel bottom head, the shell, or a combination thereof, includes a pressure vessel inlet, and wherein the pressure vessel top head, the pressure vessel bottom head, the shell, or a combination thereof includes a pressure vessel outlet.

Also disclosed is a method of transferring heat between a first fluid and a second fluid, the method including: providing the heat exchanger; directing a first fluid into a pressure vessel inlet of the pressure vessel; and directing a second fluid into the inlet of the heat exchanger core to exchange heat between the first fluid and the second fluid.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other advantages and features of this disclosure will become more apparent by describing in further detail exemplary embodiments thereof with reference to the accompanying drawings, in which:

FIG. 1A is a schematic cut-away view of an embodiment of a heat exchanger;

FIG. 1B is a schematic cut-away view of another embodiment of the heat exchanger;

FIG. 2 is a cross-sectional diagram showing a top view of an embodiment of a first casing, a second casing, and a pressure vessel;

FIG. 3 is a schematic cut-away view of another embodiment of the heat exchanger;

FIG. 4 is a cross-sectional view of an embodiment of the heat exchanger;

FIG. 5 is a schematic cut-away view of another embodiment of the heat exchanger;

FIG. 6 is a schematic cut-away view of another embodiment of the heat exchanger;

FIG. 7 is a schematic cut-away view of another embodiment of the heat exchanger;

FIG. 7A is a view showing an alternative geometry obtained by changing the aspect ratio of the footprint to height for the circular cylinder heat exchanger core geometry. Long heat transfer flow path lengths are achievable in compact volumes for the tubeless heat exchanger design with small variations in heat exchanger core footprint.

FIG. 8 is a cut-away view of an embodiment of a heat exchanger core;

FIG. 9 is a cross-sectional view of an embodiment of the heat exchanger core;

FIG. 9A is a perspective view of FIG. 9, showing a view of a preferred embodiment showing a method employing a slotted core outer casing. A rib 521 segment with rectangular cross-section is rigidly attached to the outer surface of the core inner casing 520 using a fillet weldment 522. Once the core outer casing 523 is aligned over the inner casing and rib assembly in its final position, the outer casing is rigidly attached to the inner casing and rib assembly using a seam weldment 524 that fills both sides of the gap formed between the rib outer surface and the outer edge of the beveled slot.

FIGS. 9B and 9C are side cross-section and perspective views, respectively, of a preferred embodiment showing a manufacturing method employing a slotted core outer casing. A fillet weld 511 traverses the entire length of the helical rib, rigidly securing the rib 512 to the inner casing 510. An outer core casing is manufactured with a beveled slot that exposes the outer surface of the helical rib when the outer casing 513 is concentrically aligned with the inner casing and rib assembly. The core outer casing is then rigidly attached to the inner casing and rib assembly using a butt weldment that fills the beveled slot.

FIGS. 9D and 9E are side cross-section and perspective views, respectively, of a preferred embodiment showing a method employing a slotted core outer casing. In this method, the rib structure is not a separate piece distinct from the outer core casing 526, but constructed by deforming the outer core casing 526 to contain a corrugation feature 527 whose height equals the target design gap between the inner core casing outer surface and the outer core casing inner surface. A beveled cut is then machined at the apex of the corrugation. Once the core outer casing is aligned over the inner casing 525 in its final position, the outer casing is rigidly attached to the inner casing using a seam weldment 528 that fills both sides of the gap formed in the outer casing beveled slot and involves the exposed section of the inner casing.

FIG. 9F is a top view of a preferred embodiment showing a method employing a slotted core outer casing 530 showing a rib 531 secured to the core inner casing 529 using a fillet weld. The outer casing 530 is formed from flat steel plate and its long seam is allowed to remain open so that the outer casing is deformed—under sufficient hoop stress 533—such that the gap in the casing 530 is closed and the inside diameter of the outer core casing equals the outside diameter of the inner core casing plus the diameter of the rib. Once the outer core casing is aligned in its final position of the inner casing and rib assembly, the gap in the outer core casing is collapsed further and welded 532 under hoop stress 533 to form an interference fit.

FIG. 10 is a cross-sectional view of an embodiment of the heat exchanger core;

FIG. 10A is a perspective view of FIG. 10, showing a view of a preferred embodiment showing a method for manufacturing the heat exchanger core section using a deformation of the inner casing or the outer casing. A rib 554 is formed by expanding hollow stock to form a seal. A hollow rib 554 with circular cross-section is assembled concentrically with the inner casing 552 and outer casing 553. The rib is secured to the core inner casing using a fillet weld. The hollow rib is hydraulically expanded by forcing fluid into the rib using techniques known to persons skilled in the art, thereby forming an interference fit between the inner surface of the core outer casing and the outer surface of the rib assembly. Alternatively, the core inner casing may be radially expanded—mechanically or hydraulically—to crush the hollow rib tube between the outer surface of the inner casing and the inner surface of the outer casing to form an interference fit.

FIG. 11 is a cross-sectional view of an embodiment of the heat exchanger core;

FIG. 11A is a perspective view of FIG. 11, showing a view of a preferred embodiment showing a method for manufacturing the heat exchanger core section using a mechanically shaped wall or rib. In this method, a rib 574 with triangular cross-section and 3-dimensional structure (e.g., helical rib) is wrapped concentrically around the outer surface of the core inner casing 573. The rib is secured to the core inner casing using a fillet weld 575. The core outer casing 576 is slipped over the welded core inner casing and rib assembly under pressure to deform the rib tip at its contact point with the inner surface of the outer casing to form an interference fit and seal.

FIG. 12 is a cross-sectional view of an embodiment of the heat exchanger core;

FIG. 12A is a perspective view of FIG. 12, showing a view of a preferred embodiment showing a method for manufacturing the heat exchanger core section using a mechanically shaped wall or rib. In this method, a rib 570 formed in the shape of a bar stock with an angled tip with the 3-dimension design structure (e.g., helical rib) concentrically around the outer surface of the core inner casing 569. The rib is secured to the core inner casing using a fillet weld 571. The core outer casing 572 is slipped over the welded cold inner casing and rib assembly under pressure to deform the rib tip at its contact point with the inner surface of the outer casing to form an interference fit and seal.

FIG. 13 is a cross-sectional view of an embodiment of the heat exchanger core;

FIG. 13A is a perspective view of FIG. 13, showing a view of a preferred embodiment showing a method for manufacturing the heat exchanger core section using a deformation of the inner casing or the outer casing. A rib 535 is assembled concentrically around the outer surface of the core inner casing 534 and secured to the core inner casing using a fillet weld 536. The core outer casing 537 is heated to elastically expand the outer casing so that it can be slipped around the cold inner casing and rib assembly. Once the outer core casing is heated and aligned in its final position around the inner casing and rib assembly, the outer core casing is cooled to collapse the thermally-induced expansion gap and form an interference fit 538 between the outer surface of the rib structure and the inner surface of the core outer casing.

FIG. 14 is a cross-sectional view of an embodiment of the heat exchanger core;

FIG. 14A is a perspective view of FIG. 14, showing a view of a preferred embodiment showing a method for manufacturing the heat exchanger core section using a deformation of the inner casing or the outer casing. A rib 540 is secured to the core inner casing 539 using a fillet weld 541. The core outer casing 542 is locally crushed mechanically where the rib is located, or crushed overall. Plastic deformation is achieved 543, providing the seal.

FIGS. 14B and 14C are side cross-section and perspective views, respectively, of a preferred embodiment showing a method for manufacturing the heat exchanger core section using a deformation of the inner casing or the outer casing. A rib 547 is secured to the core outer casing 546 using a fillet weld 548. The core inner casing 545, 549 is mechanically or hydraulically expanded to form an interference fit between the outer surface of the core inner casing and the inner exposed surface of the rib assembly. The dotted line 545 indicates the initial position of the inner core casing relative to the rib assembly; the solid FIG. 549 indicates the final position after plastic deformation.

FIGS. 14D and 14E are side cross-section and perspective views, respectively, of a preferred embodiment showing a method for manufacturing the heat exchanger core section using a deformation of the inner casing or the outer casing. This alternative manufacturing method does not require a separate rib component. Instead, the inner 549 and outer 550 casings are manufactured as pipe sections, aligned into their final concentric configuration, and the core upper head cap and the lower head cap are welded to the edges of the casings to create a sealed flow cavity. The outer casing is then corrugated in place at the proper pitch, with the corrugation apex extending to the inner casing outer surface 551 to form an interference fit, creating the required sealed flow path.

FIGS. 14F and 14G are side cross-section and perspective views, respectively, of a preferred embodiment showing a method for manufacturing the heat exchanger core section using a mechanically shaped wall or rib. In this method, both the rib and outer casing structures are formed in one step using an “L” shaped element welded to the core inner casing 555. Using a hot or cold forming process, the “L” shaped stock 556 is wrapped around the core inner casing 555 at the proper pitch while a continuous fillet weld 557 and seam weld 558 rigidly attach the angle stock to the inner casing 555 and form the core outer casing 556.

FIGS. 14H and 14I are side cross-section and perspective views, respectively, of a preferred embodiment showing a method for manufacturing the heat exchanger core section using a mechanically shaped wall or rib. In this method, the inner casing 559 and rib assembly 560 is “screwed” into the core outer casing. A rib 560 with circular cross-section is assembled concentrically around the outer surface of the core inner casing 559. The rib is secured to the core outer casing using a fillet weld 561. A spiral groove 564 is machined into the inner surface of the core outer casing 562. The outer casing is then threaded onto the assembly formed by the welded inner casing and rib to form an interference fit at the base of the groove 564.

FIGS. 14J and 14K are side cross-section and perspective views, respectively, of a preferred embodiment showing a method for manufacturing the heat exchanger core section using a mechanically shaped wall or rib. In this method, both the rib and outer casing structures are formed in one step using a half-pipe element 566 welded to the core inner casing 565. Instead of a separate rib structure, half-pipe steel stock 566 of the design wall thickness is wrapped around the core inner casing 565 by a hot or cold forming process. As the half-pipe stock is wrapped around the core inner casing 565 at the proper pitch, a continuous fillet weld 567 rigidly attaches the stock to the inner casing 565 to form the thermal fluid conduit in one step.

FIG. 15 is side view of an embodiment of a slotted outer casing;

FIG. 15A is a view of one manufacturing method for the slotted core outer casing 513 shown in FIGS. 9B and 9C starting with a plate 503. A sequence of beveled slots 505 is cut in the plate 503 with smaller width dimension less than or equal to the diameter of the rib and bevel angle between 0 and 90 degrees. The slotted plate is then mechanically deformed so that the left 506 and right 507 longitudinal edges are proximate and the edges are seam welded to form a right circular cylinder.

FIG. 16 is a cross-sectional view of an embodiment of the heat exchanger core;

FIG. 16A is a perspective view of FIG. 16, showing a view of a preferred embodiment showing a method employing a slotted core outer casing. A rib 516 segment with circular cross-section is rigidly attached to the outer surface of the core inner casing 515 using a fillet weldment 517. Once the core outer casing 518 is aligned over the inner casing and rib assembly in its final position, the outer casing is rigidly attached to the inner casing and rib assembly using a seam weldment that fills both sides of the gap formed between the rib outer surface and the outer edge of the beveled slot.

FIG. 17 is a cross-sectional view of an embodiment of the heat exchanger core;

FIGS. 17, 17A and 18A show complementary views of a manufacturing method variation that can be applied to overcome inspection requirements levied by certain national standards boards. In this alternative embodiment, the outer casing is comprised of two elements: an inner casing (inner O-casing) 620 and an outer casing (outer O-casing) 600. The inner O-casing and outer O-casings are manufactured so that the latter abuts proximately inside the former (which requires compatible geometries). As an application example, the rib attachment method described in FIGS. 9 and 9A are shown with the fillet weldment 640 (FIG. 17A) connecting the rectangular rib 630 (FIG. 18A) to the inner casing 610, and seam welds 650 rigidly attach the rib to the outer surface of the inner O-casing 620. The outer O-casing, once aligned and sealed onto the assembly by the head caps, ensures that the pressure of the production fluid outside the heat exchanger core is borne by the outer O-casing, while still providing a path for thermal heat transfer from the thermal fluid inside the core to the production fluid outside the core assembly; and

FIG. 18 is a cross-sectional view of an embodiment of the heat exchanger core.

DETAILED DESCRIPTION

Heat exchangers are desirably thermally compact, provide a high ratio of the thermal output to the total size of the heat exchanger, and have a design which can be manufactured at a reasonable cost. This is particularly true of gas-liquid heat exchangers, which can be incorporated into hydronic (e.g., liquid water), steam, and thermal fluid heating systems designed to deliver a hot fluid such as steam for temperature regulation, domestic hot water, or commercial or industrial process applications.

The heat exchanger and boiler industries—and persons with ordinary skill in the art in these industries—distinguish tubes used for heat transfer surfaces in tube-and-shell heat exchangers from other conduits using the following definitions: A tube is a hollow conduit with circular cross-section whose dimension is specified by the outside diameter and wall thickness is usually provided in terms of the Birmingham Wire Gauge (BWG) or Stubbs' Wire Gauge convention ranging from 5/0 gauge (0.500 inch wall thickness) to 36 gauge (0.004 inch wall thickness). Other metal conduits for thermal transfer fluid—like pipes—use different specification conventions; for example, pipe is customarily identified by “Nominal Pipe Size” (NPS) whose diameters only roughly compare to either the actual inside or outside diameter and with wall thickness defined by “Schedule Number” (SCH).

However, this definition of “tube” obfuscates the key functional properties that are important in classifying and characterizing the distinctions between tube-and shell heat exchangers—as opposed to tubeless design alternatives—particularly in regards to the state-of-the-art advance represented by the present invention. For the purposes of the detailed disclosure below, definitions are provided based on the functional distinctions between tubes and more robust heat transfer components: A tube-and-shell heat exchanger is a design classification wherein the primary location of heat exchange occurs across the wall surfaces of a numerous plurality of thin-wall (0.220 inch wall thickness) metal or metal alloy fluid conduits—which may or may not have circular cross-section—called tubes secured at either or both ends to a tubesheet, typically, by weldments. The key functional characteristics of tube-and shell heat exchangers is the presence of a large number of weldments or other mechanical fastening means (mandrel expansion for instance) between the thin-wall conduits (tubes) and the tubesheets and the presence of a numerous plurality of thin-wall conduits, both of which are susceptible to cracking and other material failures induced by corrosion, mechanical movement and thermal stresses. Because they occur within the pressure vessel, tubes, tubesheets and connection failures are difficult and expensive to service or replace, particularly in field installations.

Tube-and-shell heat exchanger designs suffer a variety of drawbacks. In a tube-and-shell heat exchanger, the heat is transferred from the thermal transfer fluid, e.g., a combustion gas generated by a fuel-fired combustor and driven under pressure through the heat exchanger by a blower, to a production fluid (e.g., liquid water, steam, or another thermal fluid) across the walls of numerous thin-walled fluid conduits, i.e. tubes, having a wall thickness of less than 0.5 centimeters (cm). The tubes are rigidly connected to a tubesheet. Operational factors including thermal stress and corrosion lead to undesirable material failures in the tubes of tube-and-shell heat exchangers, the attachment points of the tubes, and in the tubesheets. Furthermore, when a failure occurs, the fluid heating system is rendered inoperable, and the thin-walled heat exchanger tubes and/or tubesheets are difficult and costly to service or replace, particularly in field installations.

Tubeless heat exchangers refer to categories of designs that avoid the use of thin-wall (≤0.220 inch wall thickness) metal or metal alloy fluid conduits and the resulting plethora of conduit weldments to tubesheets in favor of other—less fragile—alternatives as heat transfer surfaces. In particular, tubeless conduit-and-shell heat exchangers are characterized by the presence of few fluid conduits comprising components of thicker minimum dimension (>0.220 inch) and the absence of tubesheets with many conduit-to-tubesheet weldments. In practice, tubeless conduit-and-shell heat exchangers share some common features with tube-and-shell designs including the structure and manufacture of the pressure vessel, methods of supplying hot thermal transfer fluid and cooler production fluid, and the design of regulatory control systems. However, the heat exchange core section of a tubeless conduit-and-shell heat exchanger substitutes a less fragile thermal transfer fluid conduit structure with fewer than half the distinct flow paths comprising robust metal and metal alloy components with the same or greater heat transfer capacity as compared to an equivalent tube and tubesheet structure. The engineering challenge overcome by the disclosed invention is to accomplish this substitution in an (a) equivalently compact heat exchanger volume, with (b) lower or equal material requirements, and (c) reduced or equal manufacturing cost and complexity.

Tubeless heat exchangers are also used. Tubeless heat exchangers avoid the use of the thin-walled tubes and the tubesheets associated with tube-and shell heat exchangers. Known practical designs for tubeless heat exchangers also have drawbacks. In available tubeless heat exchangers, the pressure vessel outer shell contacts a hot heat transfer fluid, e.g., along the exit path of the flue gas exhaust, resulting in a hot surface on the outside of the pressure vessel. To accommodate the hot outer surface, a refractory barrier outside the pressure vessel is provided, wherein the refractory barrier is separated from the pressure vessel by a gap through which the hot thermal transfer fluid flows, e.g., through an array of longitudinal ribs, thereby transferring thermal energy from the thermal transfer fluid into the outside of the shell, and ultimately transferring heat to the production fluid. Such tubeless designs suffer from refractory deterioration and loss of thermal efficiency due to some amount of heat being transferred into and through cracks in the refractory layer, and ultimately into the environment around the boiler. Additionally, flue gas, which can comprise CO, can leak through the cracks in the refractory layer and into occupied areas, instead of flowing to a flue gas discharge stack, creating health hazard. Furthermore, the hot outer surface of the pressure vessel presents safety issues due to the temperature of the skin which overlays the refractory material and due to leaking of thermal transfer fluid (e.g. flue gas) through cracks in the refractory material.

The disclosed heat exchanger provides a variety of features. For example, in the disclosed heat exchanger there is no direct contact between the thermal transfer fluid and the outer surface of the pressure vessel shell, thereby obviating the need for a refractory lining and avoiding safety, maintenance, and reliability concerns from a hot pressure vessel outer shell. Furthermore, the disclosed heat exchanger avoids use of thin-walled tubing, thereby avoiding the inherent fragility and susceptibility to material failure and corrosion of thin-walled tubing. The disclosed heat exchanger can be provided using metal alloy tubing having an average wall thickness of 0.5 to 5 cm, for example, as the primary member between the thermal transfer fluid and the production fluid, and thus can avoid the fragility problems associated with thin-walled tubing. In an embodiment, the disclosed heat exchanger can also avoid tight turnabouts in flow passages for both the thermal transfer fluid and the production fluid, thereby avoiding configurations that would be susceptible to fouling, clogging, and corrosion blockage. In addition, the disclosed heat exchanger provides for improved compactness (i.e., energy density, having the units of kilowatts per cubic meter, kW/m³) and improved performance characteristics compared to tube-and-shell heat exchanger alternatives of the same production capability. As is further disclosed herein, in an embodiment of the disclosed heat exchanger all outer surfaces of the heat exchanger core are contacted by the production fluid, thereby fully utilizing the outer surfaces of the heat exchanger core for thermal energy transfer and avoiding thermal stress in the heat exchanger core. The efficiency of the disclosed design provides for reduced material requirements and reduced manufacturing complexity.

A heat exchanger comprises: a heat exchanger core comprising a top head; a bottom head; a first casing disposed between the top head and the bottom head; a second casing disposed between the top head and the bottom head, wherein an inner surface of the first casing is opposite an inner surface of the second casing; an inlet on the first casing, the second casing, or combination thereof; an outlet on the first casing, the second casing, or combination thereof; a rib disposed between the first casing and the second casing, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet; a pressure vessel; an inlet member on the inlet, which connects the inlet to an outside of the pressure vessel; and an outlet member on the outlet, which connects the outlet to an outside of the pressure vessel, wherein the bottom head, the first casing, and the second casing are contained entirely within the pressure vessel, and wherein “inner surface” when used to indicate a surface of the first casing or the second casing is defined relative to the flow passage. Thus the inner surface of the first casing, the inner surface of the second casing, and the rib define the flow passage.

In an embodiment the first casing can be surrounded by the second casing, in which case the first casing may be an inner casing and the second casing may be an outer casing. Alternatively, the second casing can be surrounded by the first casing, in which case the second casing may be an inner casing and the first casing may be an outer casing. As shown in FIG. 1A, a heat exchanger 100 comprises: a heat exchanger core 110 comprising a top head 112; a bottom head 114; a first casing 116 disposed between the top head and the bottom head; a second casing 118 disposed between the top head and the bottom head, wherein an inner surface 116A of the first casing 116 is opposite an inner surface 118A of the second casing; an inlet 120 on the second casing; an outlet 122 on the first casing; a rib 124 disposed between the first casing and the second casing, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet; a pressure vessel 150; an inlet member 152 on the inlet and which connects the inlet to an outside of the pressure vessel; and an outlet member 154 on the outlet and which connects the outlet to an outside of the pressure vessel, wherein the bottom head, the first casing, and the second casing are contained entirely within the pressure vessel. The inner surface 116A of the first casing and the inner surface 118A of the second casing are interior to the flow passage defined by the first casing 116, the second casing 118, and the rib 124. Also shown in FIG. 1A is the pressure vessel top head 160, the pressure vessel bottom head 162, and the pressure vessel shell 164 which is disposed between the pressure vessel top head and the pressure vessel bottom head. The pressure vessel top head, the pressure vessel bottom head, or combination thereof may comprise an opening for a conduit (not shown in FIG. 1A). The conduit is connected to the inlet member 152, and may pass through the pressure vessel top head 160 and the top head 112 of the heat exchanger core.

Another embodiment of the heat exchanger core is shown in FIG. 1B. As shown in FIG. 1B, a curved inlet member 152A may be connected to an inlet 120A. Also shown in FIG. 1B is a conduit 170 which connects the inlet member to an outside of the heat exchanger. For example, as shown in FIG. 1B, the conduit may pass through the pressure vessel top head and the top head of the heat exchanger core.

The top head, the bottom head, the first casing, the second casing, the inlet, the outlet, the rib, the pressure vessel, the inlet member, and the outlet member, can each independently comprise any suitable material. Use of a metal is specifically mentioned. Representative metals include iron, aluminum, magnesium, titanium, nickel, cobalt, zinc, silver, copper, and an alloy comprising at least one of the foregoing. Representative metals include carbon steel, mild steel, cast iron, wrought iron, a stainless steel such as a 300 series stainless steel or a 400 series stainless steel (e.g., 304, 316, or 439 stainless steel), Monel, Inconel, bronze, and brass. Specifically mentioned is an embodiment in which the heat exchanger core and the pressure vessel each comprise steel, specifically mild steel.

The first casing and the second casing may be coaxial, and may be concentric. In an embodiment, the first casing and the second casing are coaxial, as shown in FIGS. 1A, 1B, and 2. Non-coaxial configurations are also contemplated.

The first casing and the second casing of the heat exchanger core may have any suitable shape and may each independently have a circular cross-sectional shape, an elliptical cross-sectional shape, an oval cross-sectional shape, a stadium cross-sectional shape, a semicircular cross-sectional shape, a square cross-sectional shape, a rectangular cross-sectional shape, a triangular cross-sectional shape, or combination thereof. For example, shown in FIG. 3 is an embodiment of a heat exchanger 300 comprising a heat exchanger core 310 having a triangular cross-sectional shape. An embodiment in which the first casing, e.g., the inner casing, and the second casing, e.g., the outer casing, each have a cylindrical shape is specifically mentioned.

In an embodiment, the first casing and the second casing may have a same cross-sectional shape, however other configurations are contemplated. For example, the heat exchanger core may comprise a first casing having a triangular cross-sectional shape and a second casing having a cylindrical cross-sectional shape.

The first casing and the second casing may each independently have a largest outer diameter of 15 centimeters (cm), 25 cm, or 30 cm to 350 cm, 650 cm, or 1,400 cm, wherein the foregoing upper and lower bounds can be independently combined. For example, the first casing and the second casing may each independently have a largest outer diameter of 15 cm to 1,400 cm. An embodiment in which the first casing and the second casing each independently have a largest outer diameter of 30 cm to 350 cm is preferred. Alternatively, the first casing and the second casing may each independently have a largest outer diameter of 50 cm, 100 cm, or 200 cm to 500 cm, 700 cm, or 1,400 cm, wherein the foregoing upper and lower bounds can be independently combined.

The first casing and the second casing may each independently have a maximum height of 15 cm, 25 cm, or 30 cm to 350 cm, 650 cm, or 1,400 cm, wherein the foregoing upper and lower bounds can be independently combined, and wherein the height is determined in a direction of a major axis. For example, the first casing and the second casing may each independently have a maximum height of 15 cm to 1,400 cm. Alternatively, the first casing and the second casing may each independently have a height of 50 cm, 100 cm, or 200 cm to 500 cm, 700 cm, or 1,400 cm, wherein the foregoing upper and lower bounds can be independently combined.

An embodiment in which the first casing and the second casing each independently have a largest outer diameter of 30 cm to 350 cm and a height of 50 cm to 1,000 cm is preferred.

A top head is disposed on a first end of the first casing and the second casing, and a bottom head is disposed on a second opposite end of the first casing and the second casing. The top head and the bottom head may each independently be rigidly attached to the first casing and the second casing by any suitable method, such as by a weld, an adhesive, a fastener, or a combination thereof. An embodiment in which the top head and the bottom head are each welded to the first casing and the second casing is specifically mentioned. As shown in FIG. 1A, the top head and the bottom head of the heat exchanger are distinct members. However, other designs are contemplated. For example, the top head and the bottom head may each independently be formed by providing a weld seam between the first casing and the second casing. Alternatively, the ends of the first casing and the second casing may be contacted, e.g., pinched together or rolled, to form the top head and the bottom head.

A thickness, e.g., an average thickness, of the top head, the bottom head, the first casing, and the second casing may be any suitable dimension, and the thickness of the top head, the bottom head, the first casing, and the second casing may each independently be 0.5 cm, 0.6 cm, 0.7 cm, or 1 cm to 5 cm, 4 cm, 3.5 cm, or 3 cm, wherein the foregoing upper and lower bounds can be independently combined. An embodiment in which the top head, the bottom head, the first casing, and the second casing each independently have a thickness of 0.5 cm to 1 cm is specifically mentioned.

An inner surface 116A of the first casing 116, an inner surface 118A of the second casing 118, and the rib 124 define a flow passage between the inlet and the outlet of the heat exchanger core, which comprises, e.g., consists of, the first casing, the second casing, the rib, and the top head and the bottom head of the heat exchanger core. It has been surprisingly discovered that certain configurations of the flow passage provide improved performance, including a desirable combination of pressure drop between the inlet and the outlet, and thermal performance. This improvement can be parameterized in terms of an aspect ratio of the flow passage, wherein the aspect ratio of the flow passage defined as the maximum centerline dimension divided by the minimum centerline dimension of the flow passage, where both dimensions are determined normal to a flow direction and perpendicular to each other, and wherein the shorter dimension is defined at the midpoint of the longer dimension. It has been further surprisingly discovered that configurations wherein an aspect ratio of the flow passage is 3, 5, 10, 100, 200 or 500, preferably 10 to 100, provide an improved combination of pressure drop and thermal performance, wherein the foregoing upper and lower bounds can be independently combined.

Determination of the aspect ratio is illustrated in FIG. 4, which indicates determination of the height h and the width w of an embodiment of the flow passage. As shown in FIG. 4, the height h can be determined between opposite surfaces of a same rib, e.g., between a first rib surface 124A, and a second rib surface 124B when viewed in a cross-sectional dimension, and the width w is determined between and inner surface 116A of the first casing 116 and an inner surface 118A of the second casing 118. Alternatively, for example when a plurality of ribs are used, the height h can be determined between opposite surfaces of neighboring ribs. For example, the height h of the flow passage may be 0.6 cm to 600 cm, and may be 0.6 cm, 1 cm, 2 cm, 4 cm, 10 cm, 20 cm, 40 cm, 80 cm, or 160 cm to 600 cm, 550 cm, 500 cm, 450 cm, 400 cm, 350 cm, 300 cm, or 250 cm, wherein the foregoing upper and lower bounds can be independently combined. Also the width may be 0.6 cm to 600 cm, and may be 0.6 cm, 1 cm, 2 cm, 4 cm, 10 cm, 20 cm, 40 cm, 80 cm, or 160 cm to 600 cm, 550 cm, 500 cm, 450 cm, 400 cm, 350 cm, 300 cm, or 250 cm, wherein the foregoing upper and lower bounds can be independently combined. In a preferred embodiment, the height is 20 cm to 60 cm and the width is 1 cm to 4 cm. In a more preferred embodiment, the height is 40 cm to 45 cm and the width is 1.2 cm to 1.9 cm. In another more preferred embodiment, the height is 45 cm to 50 cm and the width is 1.5 cm to 3 cm.

Any suitable number of ribs may be used. For example, as shown in FIG. 1A, a single rib may be used. Alternatively as shown in FIG. 5, a plurality of ribs may be used such as 2 to 100 ribs, e.g., 2, 4, or 8 to 100, 50, or 10 ribs, wherein the foregoing upper and lower bounds can be independently combined. Also, the rib may have any suitable configuration. In an embodiment, the rib may have a helical shape, a stepped shape, a shape of a segment of a circle, a shape of a segment of a helix, or a combination thereof. For example, as shown in FIG. 1A, the rib 124 may have a helical shape. As shown in FIG. 3, a rib 324 may have a spiral triangular shape. Alternatively, as shown in FIG. 5, a rib 524 may have a shape of a segment of a circle. Alternatively, as shown in FIG. 6, a rib 624 may have a stepped shape. In yet another embodiment, as shown in FIG. 7, a rib 724 may have a linear shape.

The rib may have any suitable cross-sectional shape. In an embodiment, the rib may have a circular cross-sectional shape, an annular cross-sectional shape, an elliptical cross-sectional shape, an oval cross-sectional shape, a stadium cross-sectional shape, a semicircular cross-sectional shape, a square cross-sectional shape, a rectangular cross-sectional shape, a triangular cross-sectional shape, or combination thereof. For example, as shown in FIG. 1A, the rib may have a circular cross-sectional shape. Alternatively, and as shown in FIG. 8, a rib 824 may have a square cross-sectional shape. In yet another embodiment, as shown in FIG. 9, a rib 924 may have a rectangular cross-sectional shape. In yet another embodiment, as shown in FIG. 10, a rib 1024 may be tubular, i.e., have a hollow center, and may have a stadium cross-sectional shape. In yet another embodiment, as shown in FIG. 11, a rib 1124 may have a triangular cross-sectional shape. Alternatively, the rib may have a rectilinear shape, and if desired the rib may be bent to provide a bent rectilinear rib 1224 as shown in FIG. 12.

FIGS. 10 and 10A show another embodiment that has been reduced to practice for manufacturing the heat exchanger core section using a deformation of the inner casing, the outer casing or both. In this alternative manufacturing method, the rib is formed by expanding hollow rib stock to form a seal. A hollow rib 554 with circular cross-section is assembled concentrically with the inner casing 552 and outer casing 553. The rib is secured to the core inner casing using a fillet weld. The hollow rib is hydraulically expanded under pressure using techniques known to persons with ordinary skill in the art to deform the hollow rib, thereby forming an interference fit between the inner surface of the core outer casing and the outer surface of the rib assembly. Alternatively, the core inner casing may be mechanically or hydraulically expanded using techniques known to persons with ordinary skill in the art to crush the hollow rib between the outer surface of the inner casing and the inner surface of the outer casing, thereby forming an interference fit. The assembly is completed by welding the core upper head cap and the lower head cap to the edges of the casings to create a sealed flow cavity.

FIGS. 11 and 11A show another embodiment that has been reduced to practice for manufacturing the heat exchanger core section using a mechanically shaped wall, rib or both. In this alternative manufacturing method, a rib 574 with triangular cross-section and 3-dimensional structure (e.g., helical rib) is wrapped concentrically around the outer surface of the core inner casing 573. The rib is secured to the core inner casing using a fillet weld 575. The core outer casing 576 is forced over the welded core inner casing and rib assembly under pressure to deform the rib tip at its contact point with the inner surface of the outer casing to form an interference fit and seal. The assembly is completed by welding the core upper head cap and the lower head cap to the edges of the casings to create a sealed flow cavity.

FIGS. 12 and 12A show another embodiment that has been reduced to practice for manufacturing the heat exchanger core section using a mechanically shaped wall, rib or both. In this alternative manufacturing method, a rib 570 formed in the shape of a bar stock with an angled tip possessing the target 3-dimension design structure (e.g., helical rib) is concentrically around the outer surface of the core inner casing 569. The angle of the outer tip is selected to be greater than 0 degree and less than 90 degrees depending upon the elastic properties of the metal or metal alloy stock. The rib is secured to the core inner casing using a fillet weld 571. The core outer casing 572 is forced over the welded cold inner casing and rib assembly under pressure to deform the rib tip at its contact point with the inner surface of the outer casing to form an interference fit and seal. The assembly is completed by welding the core upper head cap and the lower head cap to the edges of the casings to create a sealed flow cavity.

The rib may have any suitable cross-sectional dimensions. In a preferred embodiment in which the rib is rectilinear, the rib may have a cross-sectional height and width of the rib may be independently selected, may be 0.3 cm to 600 cm, and may be 0.3 cm, 0.5 cm, 0.6 cm, 1 cm, 10 cm, or 50 cm, to 100 cm, 200 cm, 400 cm, or 600 cm, wherein the foregoing upper and lower bounds can be independently combined and wherein the height is measured in a direction of a major or longitudinal axis of the heat exchanger core and wherein the width is measured in a direction perpendicular to the longitudinal axis of the heat exchanger core. For example, a rectilinear rib may have a height of 0.3 cm to 600 cm and a width of 0.5 cm to 365 cm. A rib having a circular cross-section and having a diameter of 1 cm to 5 cm is specifically mentioned. In an embodiment in which the rib is tubular, a wall thickness of the tubular rib may be 0.1 cm to 1 cm, and may be 0.1 cm, 0.2 cm, or 0.4 cm to 0.6 cm, 0.8 cm, or 1 cm, wherein the foregoing upper and lower bounds can be independently combined.

The rib may contact the first casing and the second casing, may be rigidly attached to one or both of the first casing and the second casing, or may fit loosely between the first and second casings. For example, the rib may form an interference fit with the inner surface of the first casing, the inner surface of the second casing, or a combination thereof. In another embodiment, the first casing and the rib, the second casing and the rib, or a combination thereof may be rigidly attached at one point, or at a plurality of points along the length of the rib. The attachment may be provided by any suitable attachment member, such as a weld, an adhesive, a fastener, or combination thereof. Use of a weld, such as a spot or stitch weld, is specifically mentioned. Alternatively, a continuous weld extending the length of the rib may be used. Also, the rib may be rigidly attached to the first casing by a first weld and rigidly attached to the second casing by a second weld, wherein the first weld and the second weld may be the same type of weld or may be different types of welds. The rib may be stitch-welded to the first or second casing anywhere along its length, or continuously welded along its length, to hold the rib in a selected position relative to the first casing, the second casing, or both. For example, as shown in FIG. 9, the rib may be welded to an inner surface of the first casing by a fillet weld 960 and the rib seam or butt welded to the second casing. Alternatively, the fillet weld may be used to attach the rib to the inner surface of the second casing and the rib seam or butt welded to the first casing. A seam weld, such as seam weld 962 shown in FIG. 9, may be used to rigidly attach the rib to the first casing, the second casing, or combination thereof.

FIGS. 9B and 9C show a preferred embodiment that has been reduced to practice for manufacturing the heat exchanger core section using a slotted core outer casing showing a rib 512 segment with circular cross-section rigidly attached to the outer surface of the core inner casing 510 using a fillet weldment 511. The fillet weld traverses the entire length of the helical rib, both rigidly securing it to the casing and seal the resulting interface. An outer core casing is manufactured with a beveled slot that exposes the outer surface of the helical rib when the outer casing 513 is concentrically aligned with the inner casing and rib assembly. The core outer casing is then rigidly attached to the inner casing and rib assembly using a butt weldment 514 that fills the beveled slot. The assembly is completed by welding the core upper head cap and the lower head cap to the edges of the casings to create a sealed flow cavity.

In yet another embodiment, the first casing, the second casing, or combination thereof may be deformed to secure the rib. For example, as shown in FIG. 13, the first casing, the second casing, or combination thereof may comprise a groove 1361 which is configured to accept the rib. In yet another embodiment, the first casing, the second casing, or combination thereof may be deformed to provide a ridge 1462 as shown in FIG. 14 which protrudes in a direction of and optionally contacts the rib.

FIGS. 13 and 13A show another embodiment that has been reduced to practice for manufacturing the heat exchanger core section using a deformation of the inner casing, the outer casing or both similar to the method described for FIG. 9F but eliminates the requirement for a machined cut in the outer casing: A rib 535 with circular cross-section is assembled concentrically around the outer surface of the core inner casing 534. The diameter of the rib stock has been selected to equal the design gap between the outer surface of the inner core casing and the inner surface of the outer core casing 537 when the components are assembled in their final positions. The rib is secured to the core inner casing using a fillet weld 536. The core outer casing is heated in excess of 1,100 degrees Fahrenheit to plastically expand the outer casing to the extent that it can be slipped around the cold inner casing and rib assembly. Standard calculations known to persons with ordinary skill in the art show that for a steel outer casing measuring 24 inches in outside diameter and ⅜ inch wall thickness, the expected casing expansion results in a 1/16 inch heated clearance (taking into account manufacturing clearances). This is sufficient to permit assembly of the components and still ensure the required interference fits are present in the configuration. Once the outer core casing is heated and aligned in its final position around the inner casing and rib assembly, the outer core casing is cooled to collapse the thermally-induced expansion gap and form an interference fit 538 between the outer surface of the rib structure and the inner surface of the core outer casing. The assembly is completed by welding the core upper head cap and the lower head cap to the edges of the casings to create a sealed flow cavity.

FIGS. 14 and 14A show another embodiment that has been reduced to practice for manufacturing the heat exchanger core section using a deformation of the inner casing, the outer casing or both. In this manufacturing method, the core outer casing 542 is crushed onto the rib assembly to form an interference fit. A rib 540 with circular cross-section is assembled concentrically around the outer surface of the core inner casing 539. The diameter of the rib stock has been selected to equal the design gap between the outer surface of the inner core casing and the inner surface of the outer core casing 542 when the components are assembled in their final positions. The rib is secured to the core inner casing using a fillet weld 541. The core outer casing is locally crushed by mechanical means where the rib is located, or crushed overall. This is similar to corrugation techniques known to persons with ordinary skill in the art, but the depth would only be far enough to contact and seal the outer casing with the rib. Plastic deformation is achieved 543, providing the seal. The assembly is completed by welding the core upper head cap and the lower head cap to the edges of the casings to create a sealed flow cavity.

FIGS. 14B and 14C show another embodiment that has been reduced to practice for manufacturing the heat exchanger core section using a deformation of the inner casing, the outer casing or both. In this alternative manufacturing method, the core inner casing 545, 549 is expanded onto the rib assembly to form an interference fit. A rib 547 with circular cross-section is assembled concentrically inside the inner surface of the core outer casing 546. The diameter of the rib stock has been selected to equal the design gap between the outer surface on the inner core casing and the inner surface of the outer core casing 546 when the components are assembled in their final positions. The rib is secured to the core outer casing using a fillet weld 548. The core inner casing is mechanically or hydraulically deformed using techniques known to persons with ordinary skill in the art to form an interference fit between the outer surface of the core inner casing and the inner exposed surface of the rib assembly. (The dotted line 545 indicates the initial position of the inner core casing relative to the rib assembly; the solid FIG. 549 indicates the final position after plastic deformation.) The expansion can be achieved mechanically by the application of a mandrel placed inside the inner casing and radically expanded, locally stretching the inner casing far enough to achieve plastic deformation and provide enough pressure to create the required interference seal. Alternatively, the expansion of the inner casing can be achieved hydraulically by pumping hydraulic fluid into the inner casing, similarly stretching the inner casing far enough to achieve plastic deformation to create the required interference seal. The assembly is completed by welding the core upper head cap and the lower head cap to the edges of the casings to create a sealed flow cavity.

FIGS. 14D and 14E shows another embodiment that has been reduced to practice for manufacturing the heat exchanger core section using a deformation of the inner casing, the outer casing or both. This alternative manufacturing method does not require a separate rib component. Instead the inner 549 and outer 550 casings are manufactured as pipe sections, aligned into their final concentric configuration, and the core upper head cap and the lower head cap are welded to the edges of the casings to create a sealed flow cavity. The outer casing is then corrugated in place at the proper pitch, with the corrugation apex extending to the inner casing outer surface 551 to form an interference fit, creating the required sealed flow path. Alternately, the inner casing could be corrugated radially outward to contact the inner surface of the core outer casing using similar techniques.

FIGS. 14F and 14G show another embodiment that has been reduced to practice for manufacturing the heat exchanger core section using a mechanically shaped wall, rib or both. In this alternative manufacturing method, both the rib and outer casing structures are formed in one step using an “L” shaped element welded to the core inner casing. Instead of a separate rib structure, 90 degree steel angle stock 556 is wrapped around the core inner casing 555. The wall thickness of the legs of the angle stock may be manufactured to be different to achieve a desired wall thickness of the interior rib formed compared to the exterior casing surface that is exposed. Using a hot or cold process, the angle stock 556 is wrapped around the core inner casing 555 at the proper pitch while a continuous fillet weld 557 and seam weld 558 rigidly attach the angle stock to the inner casing 557 and form the core outer casing 558, respectively. The assembly is completed by welding the core upper head cap and the lower head cap to the edges of the casings to create a sealed flow cavity.

FIGS. 14H and 14I show another embodiment that has been reduced to practice for manufacturing the heat exchanger core section using a mechanically shaped wall, rib or both. In this alternative manufacturing method, the inner casing and rib assembly is “screwed” into the core outer casing. A rib 560 with circular cross-section is assembled concentrically around the outer surface of the core inner casing 559. The rib is secured to the core outer casing using a fillet weld 561. The diameter of the rib stock has been selected to equal the design gap between the outer surface of the inner core casing and the inner surface of the outer core casing 562 when the components are assembled in their final positions plus 5-10%. A spiral grove is machined into the inner surface of the core outer casing 564. The outer casing is then threaded onto the assembly formed by the welded inner casing and rib to form an interference fit at the base of the groove 564. In this way the two pieces fit together, the rib acting like the male thread, with the groove acting like the female thread. The assembly is completed by welding the core upper head cap and the lower head cap to the edges of the casings to create a sealed flow cavity.

FIGS. 14J and 14K show another embodiment that has been reduced to practice for manufacturing the heat exchanger core section using a mechanically shaped wall, rib or both. In this alternative manufacturing method, both the rib and outer casing structures are formed in one step using a half-pipe element welded to the core inner casing. Instead of a separate rib structure, half-pipe steel stock 566 of the design wall thickness is wrapped around the core inner casing 565 by a hot or cold forming process. As the half-pipe stock is wrapped around the core inner casing 565 at the proper pitch, continuous fillet welds rigidly attach the stock to the inner casing 565 at the upper 567 and lower 568 contact points to form the thermal transfer fluid conduit in one step. The assembly is completed by welding the core upper head cap and the lower head cap to the edges of the casings to create a sealed flow cavity.

The rib may have a pitch, e.g., a slope, having any suitable angle with respect to a longitudinal axis of the heat exchanger core, the inner casing, or the outer casing. As illustrated in FIG. 1A, a pitch θ may be defined with respect to a tangent direction t, wherein the tangent direction is perpendicular to a longitudinal axis of the outer casing. In an embodiment, a pitch of the rib is 0 degrees to 90 degrees with respect to the tangent direction, and can be 0 degrees, 2 degrees, or 5 degrees to 90 degrees, 50 degrees, or 45 degrees with respect to the tangent direction, wherein the foregoing upper and lower bounds can be independently combined. A pitch of 5 degrees to 45 degrees with respect to the tangent direction is specifically mentioned. In an embodiment, the heat exchanger core comprises a plurality of ribs, and a pitch of each rib of the plurality of ribs may each independently be 0 degrees to 90 degrees with respect to the tangent direction, and can be 0 degrees, 2 degrees, or 5 degrees to 90 degrees, 50 degrees, or 45 degrees with respect to the tangent direction, wherein the foregoing upper and lower bounds can be independently combined. An embodiment in which the pitch is 5 degrees to 45 degrees with respect to the tangent direction is specifically mentioned.

In yet another embodiment, as shown in FIG. 7, the rib may be parallel to an axis, e.g., a longitudinal axis, of the first casing, the second casing, or combination thereof. In an embodiment, the heat exchanger core may comprise a plurality of ribs, and each rib may be parallel to a longitudinal axis of the first casing, the second casing, or combination thereof, for example as illustrated by rib 724 as shown in FIG. 7. In an embodiment, the heat exchanger core comprises a rib which provides a serpentine flow passage between the inlet and the outlet. The serpentine flow passage may be defined by a plurality of linear ribs, or may be defined by a combination of curved ribs and linear ribs.

FIG. 7A illuminates a third aspect of the disclosed invention showing alternative longitudinal cross-sectional geometries. The key feature of the core casing geometry relates to the achievable average thermal fluid flow path length from the inlet port to the exhaust port. This path length is a critical system design parameter: Longer thermal fluid path lengths result in greater heat transfer capability and efficiency, but also increase the heat exchanger pressure drop due to aerodynamic resistance losses. FIG. 7A shows the design flexibility achievable by changing the aspect ratio of the circumferential core diameter compared to the core height; for a fixed pitch, 2πα, aspect ratio, φ, and mean core diameter, d, the average path length (equivalent to helical arc length) scales according to the nonlinear formula dφ√{square root over (d²/4+α²)}∝d². As a result, long heat transfer flow path lengths are achievable in compact volumes for the tubeless heat exchanger design with small variations in heat exchanger core footprint—along with the resulting increases in heat transfer energy and thermal efficiency—compared to simplistic solutions available to the designer that merely involve elongated fin or tube lengths in conventional tube-and-shell heat exchanger configurations that only scale linearly with changes in footprint dimension.

For certain applications, such as to satisfy inspection requirements, a third casing may be desirable. In an embodiment, the third casing 1770 (FIG. 17) may be disposed adjacent to the concave outer surface 1780 of the second casing 1716 and between the top head and the bottom head of the heat exchanger core, e.g., as shown in FIGS. 17 and 18 for an embodiment in which the third casing 1770 is on the outer surface of the second casing 1716, and wherein the second casing is in the outer casing. For clarity, also shown in FIG. 17 is the first casing 1718 and the second casing 1716. Alternatively, the third casing 1770 may be adjacent a concave outer surface 1780 of the second casing 1716, wherein the first casing 1718 is an inner casing, if desired. Any suitable configuration of the first casing, the rib, and the second casing may be used in conjunction with the third casing. For example as shown in FIG. 18, a second casing 1816 may be used in conjunction with the third casing 1870 and a vertical rib 1824 which protrudes through a slot in the second casing 1816 and is held in place by a weld 1830.

FIGS. 17, 17A and 18A show complimentary views of a manufacturing method variation that can be applied to each of the alternative manufacturing methods described above to overcome inspection requirements levied by certain national standards boards. In this alternative embodiment, the outer casing is comprised of two elements: an inner casing (inner O-casing 620) and an outer casing (outer O-casing 600). The inner O-casing and outer O-casings are manufactured so that the latter abuts proximately inside the former (which requires compatible geometries. For example, both inner and outer O-casings have the geometrical shape of a geometric cylinder.) For each of the manufacturing methods described and illustrated in FIGS. 9B, 9C, 15A, 16, 16A, 9, 9A, 9D, 9E, 9F, 13, 13A, 14, 14A, 14B, 14C, 14D, 14E, 10, 10A, 14F, 14G, 14H, 14I, 14J, 14K, 12, 12A, 11, and 11A the rib structure is attached by either a weldment or interference fit to the inner O-casing, as described in the specification above. The outer O-casing is then aligned circumferentially outside the inner O-casing. The upper and lower head caps structurally fixed the core inner casing 610, the inner O-casing 620 and the outer O-casing 600 in a rigid assembly. To illustrate this method variation, the rib attachment method described with regard to FIG. 9 and FIG. 9A is shown with the fillet weldment 640 (FIG. 17A) connecting the rectangular rib 630 (FIG. 18A) to the inner casing 610, and the seam welds 650 rigidly attaching the rib to the outer surface of the inner O-casing 620. The outer O-casing, once aligned and sealed onto the assembly by the head caps ensures that the pressure of the production fluid outside the heat exchanger core is borne by the outer O-casing, while still providing a path for thermal heat transfer from the thermal fluid inside the core to the production fluid outside the core assembly.

The third casing may comprise a same material as is disclosed for the first casing, and may be manufactured using a same method as is disclosed for the first casing, and thus duplicative disclosure of the content and manufacture the third casing is not repeated for clarity.

The bottom head, the first casing, and the second casing of the heat exchanger core are contained entirely within the pressure vessel. In another embodiment, the top head, the bottom head, the first casing, and the second casing of the heat exchanger core are contained entirely within the pressure vessel. In yet another embodiment, an entirety of the heat exchanger core, i.e., the top head, the bottom head, the first casing, the second casing, the inlet, and the outlet are contained entirely within the pressure vessel. As used with respect to the configuration of the heat exchanger core within the pressure vessel, “entirety” means that the component referred to is fully contained within the pressure vessel. For example, when the pressure vessel is filled with a fluid, an entire outer surface of a component of the heat exchanger core which is contained entirely with the pressure vessel would be contacted by the fluid. Thus in use, e.g., when the pressure vessel is filled with a production fluid, an entirety of an outer surface 115 of the bottom head, an entirety of an outer surface 119 of the first casing, and an entirety of an outer surface 117 of the second casing can be contacted by the production fluid. In yet another embodiment the top head may also be contained entirely within the pressure vessel, in which case when the pressure vessel is filled with a production fluid, the production fluid can contact an entire outer surface 113 of the top head as well. In yet another embodiment, an entirety of the heat exchanger core, i.e., the top head, the bottom head, the first casing, the second casing, the inlet, and the outlet, is contained entirely within the pressure vessel.

The heat exchanger further comprises an inlet member 152 or 152A which connects the inlet 120 or 120A, respectively, to an outside of the pressure vessel, e.g. for providing a flow of a thermal transfer fluid, such as a combustion gas, to the inlet of the heat exchanger core. Also, an outlet member 154, which connects the outlet 122 of the heat exchanger core to an outside of the pressure vessel can be provided. Also, the pressure vessel comprises an inlet 155, and an outlet 156 for providing a flow of a production fluid into and out of the pressure vessel.

The heat exchanger may be used to exchange heat between any suitable fluids, i.e., a first fluid and the second fluid, wherein the first and second fluids may each independently be a gas or a liquid. Thus the disclosed heat exchanger may be used as a gas-liquid, liquid-liquid, or gas-gas heat exchanger. In a preferred embodiment the first fluid, which is directed through the heat exchanger core, is a thermal transfer fluid, and may be a combustion gas, e.g., a gas produced by fuel fired combustor, and may comprise water, carbon monoxide, carbon dioxide, or combination thereof. Also, the second fluid, which is directed through the pressure vessel and contacts an entire outer surface of the heat exchanger core, is a production fluid and may comprise water, steam, oil, a thermal fluid, or combination thereof. The thermal fluid may comprise an ester, a diester, a glycol, a silicone, water, a petroleum oil, a mineral oil, or a chlorofluorocarbon such as a halogenated fluorocarbon, a halogenated chlorofluorocarbon, or a perfluorocarbon. A combination comprising at least one of the foregoing may be used. A thermal fluid comprising glycol and water is specifically mentioned. For example, the thermal fluid may be formulated from an alkaline organic or inorganic compound and used in diluted form with a concentration ranging from 3 weight percent to 10 weight percent, based on a total weight of the thermal fluid.

For example, the second fluid may comprise water, and may be used as a production fluid in a domestic, commercial, or industrial heating application. The first fluid, e.g., the thermal transfer fluid, which is directed through the inlet member, through the flow passage of the heat exchanger core, and out the outlet member, does not contact the pressure vessel. As a result, thermal heat energy transfer occurs between the hot first fluid flowing inside the core to the second fluid separately flowing in the pressure vessel. As noted above, the second fluid contacts an entire outer surface of the of the heat exchanger core and at no point does the surface of the pressure vessel contact the first fluid. Because the pressure vessel does not contact the first fluid, which can have a temperature of 10° C. to 1800° C., such as 10° C., 50° C., 100° C., 200° C., or 400° C. to 1800° C., 1600° C., 1400° C., 1200° C., or 1000° C., wherein the foregoing upper and lower bounds can be independently combined, the exterior surface of the pressure vessel remains relatively cool and use of insulation, e.g., a refractory material, to insulate the pressure vessel can be avoided. An embodiment in which the first fluid has a temperature of 100° C. to 1350° C. is specifically mentioned.

The pressure vessel top head, the pressure vessel bottom head, and the pressure vessel shell may each independently have any suitable shape, and may be rectilinear or curvilinear, and may be flat, domed, or spherical. For example, as shown in FIG. 1A, the pressure vessel top head and the pressure vessel bottom head may have a flat shape. Alternatively, as shown in FIG. 1B, the pressure vessel top head and the pressure vessel bottom head may have a curved shape. Also, the pressure vessel shell may have any suitable shape, maybe curvilinear or rectilinear, and may be cylindrical as shown in FIG. 1A.

Also disclosed is a method of manufacturing a heat exchanger core, the method comprising: providing a first casing, e.g., an inner casing; disposing a rib on an inner surface of the first casing; providing a second casing, e.g., an outer casing, comprising a slot; aligning the rib and the slot by disposing the first casing on the second casing; rigidly attaching the rib to the second casing; disposing a top head on a first end of the second casing; disposing a bottom head on a second end of the second casing; disposing an inlet on the first casing, the second casing, or a combination thereof; and disposing an outlet on the first casing, the second casing, or a combination thereof to manufacture the heat exchanger core, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet. In an embodiment the first casing is in inner casing. Alternatively, the first casing may be an outer casing. The flow passage may be defined by the inner surface of the first casing, the inner surface of the second casing and the rib.

The first casing may be a tube or a section of a pipe, for example, and may be provided by rolling a flat sheet and connecting opposite edges to provide a tube. The rib may be disposed on the inner surface of the first casing by any suitable method, such as by welding, adhesive bonding, or fastening, or combination thereof. In a preferred embodiment the rib is welded to the surface of the first casing. An embodiment in which the rib is welded to the surface of the first casing using a fillet weld is specifically mentioned. The fillet weld may transverse an entire length of the rib, or may be present on a portion of the rib, such as 10% to 90% of the total rib length, e.g., 10%, 15%, or 20% to 90%, 80%, or 70% of the total rib length, wherein the foregoing upper and lower bounds can be independently combined. An embodiment in which the fillet weld transverses 100% of the total rib length is specifically mentioned. A slotted casing 1500 may comprise a slot 1510, and optionally an outlet 1522, as shown in FIG. 15, for example. The second casing may be provided, for example, by cutting a slot at a selected pitch angle in a pipe. The slot may have a width selected to correspond to a dimension of the rib and may have a width of 1 millimeter (mm) to 5 centimeters (cm). In an embodiment, a width of the slot is 1 mm, 2 mm, or 4 mm to 5 cm, 3 cm, or 1 cm, wherein the foregoing upper and lower bounds can be independently combined. An embodiment in which a width of the slot is 2 mm to 2 cm is specifically mentioned. Also, in an embodiment the slot may comprise a bevel to facilitate the formation of a weld between the outer casing and the rib. The outer casing comprising the slot may be disposed on the inner casing comprising the rib and then the rib rigidly attached to the outer casing by welding, for example. Use of a full penetration weld or butt weld is specifically mentioned, and the weld may be selected based upon the shape and dimensions of the rib. The top head of the heat exchanger core may be welded to the first end of each of the first casing and the second casing, and the bottom head of the heat exchanger core welded to the opposite second end of each of the first casing and the second casing, for example, to form a cavity between the first casing and the second casing for the thermal transfer fluid. The inlet and the outlet may each independently be disposed, e.g., welded, on the first casing the second casing or combination thereof. An embodiment in which the inlet is disposed on an outer surface of the first casing, and in which the outlet is disposed on an outer surface of the second casing is specifically mentioned. Also, if desired, an inlet member, which connects the inlet to an outside of the pressure vessel, e.g., to the source of a thermal transfer fluid, may be disposed on the inlet. In addition, an outlet member, which connects the outlet to an outside of the pressure vessel, e.g., to a vent, may be disposed on the outlet.

In an embodiment, the dimensions of the rib and the dimensions of the gap in the slotted casing may be selected so that when the first and second casings are in their final positions, an outer surface of the rib 1610 protrudes up to, or beyond, an outer surface of the second casing 1620, as shown in FIG. 16. As shown in FIG. 16, the rib and the second casing may be rigidly attached using a seam weld, for example.

FIGS. 16 and 16A show another embodiment that has been reduced to practice for manufacturing the heat exchanger core section using a slotted core outer casing showing a rib 516 segment with circular cross-section rigidly attached to the outer surface of the core inner casing 515 using a fillet weldment 517. The diameter of the rib stock and narrowest dimension of the beveled gap in the outer casing 518 has been selected so that when the inner and outer casings are in their final positions, the outer surface of the rib protrudes up to—or beyond—the outer surface of the outer core casing. Once the core outer casing is aligned over the inner casing and rib assembly in its final position, the outer casing is rigidly attached to the inner casing and rib assembly using a seam weldment 519 that fills both sides of the gap formed between the rib outer surface and the outer edge of the beveled slot. The assembly is completed by welding the core upper head cap and the lower head cap to the edges of the casings to create a sealed flow cavity.

Alternatively, a cross-sectional width of a rectilinear rib can be selected to the equal to or greater than a desired gap between the first casing and the second casing plus the width of the first casing, the second casing, or combination thereof. As shown in FIG. 9, the outer casing may be aligned over the inner casing and the rib assembly, and then the outer casing rigidly attached to the rib by welding, for example. Use of a seam weld is specifically mentioned.

FIG. 9 and FIG. 9A show another embodiment that has been reduced to practice for manufacturing the heat exchanger core section using a slotted core outer casing showing a rib 521 segment with rectangular cross-section rigidly attached to the outer surface of the core inner casing 520 using a fillet weldment 522. The cross-sectional height of the rib has been selected equal or greater than the sum of the design target gap between the inner core casing outer surface and the outer core casing 523 inner surface plus the width of the core outer casing; as a result, the outer rib exposed surface protrudes beyond the outer surface of the outer core when assembled in its final position. Once the core outer casing is aligned over the inner casing and rib assembly in its final position, the outer casing is rigidly attached to the inner casing and rib assembly using a seam weldment 524 that fills both sides of the gap formed between the rib outer surface and the outer edge of the beveled slot. The assembly is completed by welding the core upper head cap and the lower head cap to the edges of the casings to create a sealed flow cavity.

FIGS. 9D and 9E show another embodiment that has been reduced to practice for manufacturing the heat exchanger core section using a slotted core outer casing. In this method, the rib structure is not a separate piece distinct from the outer core casing 526; instead, it is constructed by deforming the outer core casing 526 using mechanical means known to persons with ordinary skill in the art of complex metal and metal alloy machining to contain a corrugation feature 527 whose height equals the target design gap between the inner core casing outer surface and the outer core casing inner surface. The beveled cut is then machined at the apex of the corrugation; as a result, the outer surface of the inner core casing 525 is exposed when the outer core is aligned with the inner casing and assembled in its final position. Once the core outer casing is aligned over the inner casing in its final position, the outer casing is rigidly attached to the inner casing using a seam weldment 528 that fills both sides of the gap formed in the outer casing beveled slot and the involves the exposed section of the inner casing. The assembly is completed by welding the core upper head cap and the lower head cap to the edges of the casings to create a sealed flow cavity.

FIG. 9F shows another embodiment that has been reduced to practice for manufacturing the heat exchanger core section using a slotted core outer casing showing a rib 531 segment with circular cross-section assembled concentrically around the outer surface of the core inner casing 529. The diameter of the rib stock has been selected to equal the design gap between the outer surface of the inner core casing 529 and the inner surface of the outer core casing 530 when the components are assembled in their final positions. The rib is secured to the core inner casing using a fillet weld under sufficient hoop stress 533—the outer casing is deformed such that the gap in the casing is closed and the inside diameter of the outer core casing equals the outside diameter of the inner core casing plus the diameter of the rib. Once the outer core casing is aligned in its final position of the inner casing and rib assembly, the gap in the outer core casing is collapsed under hoop stress to form an interference fit between: (i) the inner casing outer surface and the inner surface of the rib structure; and, (ii) the outer surface of the rib structure and the inner surface of the outer casing. The assembly is completed by welding the core upper head cap and the lower head cap to the edges of the casings to create a sealed flow cavity.

In another embodiment, the method of manufacturing a heat exchanger core comprises providing a first casing; disposing a rib on an inner surface of the first casing; providing a second casing member; disposing, e.g., wrapping, the second casing member on an outer surface of the first casing; rigidly attaching longitudinal edges of the second casing member to form a second casing; disposing a top head on an upper end of each of the first casing and the second casing; disposing a bottom head on a lower end of each of the first casing and the second casing; disposing an inlet on the first casing, the second casing, or combination thereof; and disposing an outlet on the first casing, the second casing, or combination thereof to manufacture the heat exchanger core; wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet. The flow passage may be defined by an inner surface of the first casing, an inner surface of the second casing and the rib. In an embodiment, the first casing is an inner casing and the second casing is outer casing. Alternatively, the first casing may be an outer casing and the second casing may be in inner casing. Details of the disposing, e.g., welding, are similar to as disclosed above, and thus repeated description is not included for clarity.

If desired, a third casing may be disposed on an outer surface of the second casing, as shown in FIG. 17. A method of disposing the third casing can be the same as disclosed for the second casing, and repetitive disclosure is not included herein for clarity.

One embodiment of the manufacturing method reduced to practice for manufacturing the slotted core outer casing 513 shown in FIGS. 9B and 9C can be accomplished in a sequence of steps starting with a plate with thickness equal to the design wall thickness of the outer casing, width equal to ad, where d is the inside diameter of the core outer casing and length equal to the height of the concentric inner and outer casing pair. FIG. 15A shows the physical layout of the plate. A hole is cut into the plate to receive the Fluid 1 inlet port at a later manufacturing step. A sequence of beveled slots 505 are cut in the plate with narrow width dimension less than or equal to the diameter of the rib and bevel angle between 0 and 90 degrees. The slotted plate is then mechanically deformed so that the left 506 and right 507 longitudinal edges are proximate and the edges are seam welded to form a right circular cylinder.

An alternative means for manufacturing the slotted core outer casing 513 shown in FIGS. 9B and 9C is to cut the beveled slot 505 (FIG. 15A) at the pitch angle corresponding to the helical pitch of the rib directly in a stock steel pipe using methods known to persons with ordinary skill in the art of machining complex metal or metal alloy geometries with target inside and outside diameter dimensions of the heat exchanger core outer casing.

The casing comprising a slot may be provided from a flat metal sheet. In an embodiment, the providing the casing comprising the slot comprises providing a metal sheet, cutting a slot in the metal sheet to provide a slotted metal sheet, wherein a direction of the slot forms an angle of 0 degrees to 90 degrees, e.g., 0 degrees, 2 degrees, or 5 degrees to 90 degrees, 50 degrees, or 45 degrees with respect to a longitudinal edge of the metal sheet, wherein the foregoing upper and lower bounds can be independently combined, bending the metal sheet so that longitudinal edges of the metal sheet are adjacent each other, and joining the longitudinal edges to provide the slotted casing. In an embodiment, as illustrated in FIG. 15, the slotted casing 1500 comprising the slot 1510 and the outlet 1522 can be provided by rolling a flat slotted sheet to form a cylinder and then connecting, e.g., welding, the longitudinal edges of the metal sheet to form the cylinder. An embodiment in which a direction of the slot forms an angle of about 2 degrees to 45 degrees with respect to the longitudinal edge of the metal sheet is specifically mentioned. The configuration and angle of the slot may be selected to correspond to a pitch angle of the rib. The longitudinal edges may be defined using a seam weld, for example. If desired, the method may further comprise cutting an opening in the metal sheet to form the outlet. The dimensions of the metal sheet may be selected in accordance with a desired diameter of the outer casing.

Alternatively, the heat exchanger core can be manufactured by heating an outer casing of the first and second casings to thermally expand the outer casing, or cooling an inner casing of the first and second casings to contract the inner casing, disposing the first casing on the second casing, and then thermally equilibrating the first casing and the second casing. In an aspect, a method of manufacturing a heat exchanger core comprises providing an first casing; disposing a rib on an inner surface of the first casing; providing a second casing; heating or cooling at least one of the first casing and the second casing to expand an outer casing of the first casing and the second casing or contract an inner casing of the first casing and the second casing; disposing the first casing on the second casing; thermally equilibrating the first casing and the second casing to contact at least one of an inner surface of the first casing and the rib and an inner surface of the second casing and the rib; disposing a top head on an upper end of each of the first casing and the second casing; disposing a bottom head on a lower end of each of the first casing and the second casing; disposing an inlet on the first casing, the second casing, or combination thereof; disposing an outlet on the first casing, the second casing, or combination thereof to manufacture the heat exchanger core; wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet.

The casing which is heated, e.g., the first casing or the second casing, may be heated to 200° C. to 2000° C., e.g., 200° C., 300° C., or 400° C. to 2,000° C., 1,000° C., 800° C., or 600° C., wherein the foregoing upper and lower bounds can be independently combined, to expand the casing so that it may be disposed around the colder other casing, e.g., the second casing or the first casing and rib assembly. Heating to 300° C. to 800° C. is specifically mentioned. Once the second casing is in its desired position, it may be allowed to cool and contract and form an interference fit between the rib and an inner surface of the second casing. Alternatively or in addition, the first casing or the second casing may be cooled to −196° C. to 20° C., e.g., −196° C., −150° C., or −80° C. to −20° C., −10° C., 0° C., 10° C., or 20° C., wherein the foregoing upper and lower bounds can be independently combined, to contract an inner casing of the first casing or the second casing so that may be disposed within the hotter other casing. Cooling to −150° C. to −20° C. is specifically mentioned. Thermally equilibrating the first casing and the second casing can form an interference fit between the rib and an inner surface of the second casing.

In yet another aspect, the first casing, the second casing, or a combination thereof may be deformed to contact the rib. In an aspect, the method of manufacturing a heat exchanger core comprises providing an first casing; disposing a rib on an inner surface of the first casing; disposing a second casing on the first casing and the rib; deforming at least one of the first casing and the second casing to contact at least one of the first casing and the rib and the second casing and the rib; disposing a top head on an upper end of each of the first casing and the second casing; disposing a bottom head on a lower end of each of the first casing and the second casing; disposing an inlet on the first casing, the second casing, or combination thereof; and disposing an outlet on the first casing, the second casing, or combination thereof to manufacture the heat exchanger core, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet.

The deforming may comprise providing a concave surface or a convex surface. The casing comprising the deformation may be provided by disposing a casing member on the first casing and the rib, and then compressing or expanding the casing member to form a second casing comprising the concave surface. Alternatively, the casing member may be deformed, for example by stamping, to provide a casing member comprising the convex surface. In yet another embodiment, the first casing may be expanded, e.g., hydraulically or pneumatically, for example, or contracted by crushing, for example, to expand or contract the first casing and the rib so that the rib contacts the second casing. The pressure, force or stress applied to provide the desired deformation can be selected based on the geometry, dimension, component materials, and manufacturing method used to dispose the inner and outer casings. Specifically, the magnitude of the pressure, force or stress can be determined based on the yield stress of the component materials undergoing deformation using industry standard methods and data known to persons of skill in the art of manufacturing.

In yet another embodiment, a method of manufacturing a heat exchanger core comprises providing a first casing; disposing a tubular rib on the first casing; disposing the first casing on a second casing; expanding the rib so that the expanded rib contacts the first casing and the second casing; disposing a top head on an upper end of each of the first casing and the second casing; disposing a bottom head on a lower end of each of the first casing and the second casing; disposing an inlet on the first casing, the second casing, or combination thereof; and disposing an outlet on the first casing, the second casing, or combination thereof to manufacture the heat exchanger core, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet.

The tubular rib may be expanded by any suitable method, and may be expanded pneumatically or hydraulically.

In yet another embodiment, a method of manufacturing the heat exchanger core comprises providing a first casing; disposing a rib on an inner surface of the first casing; providing a second casing, wherein an inner surface of the second casing comprises a groove, which is configured to receive the rib; rotating the first casing relative to the second outer casing to thread the first casing into the second casing to dispose the first casing on the second casing; disposing a top head on an upper end of each of the first casing and the second casing; disposing a bottom head on a lower end of each of the first casing and the second casing; disposing an inlet on the first casing, the second casing, or combination thereof; and disposing an outlet on the first casing, the second casing, or combination thereof to manufacture the heat exchanger core, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet. If desired, the method may further comprise expanding or contracting the first casing so that the rib contacts the first casing and the second casing.

The groove may be a spiral groove and may be configured to permit screwing the first casing onto the second casing and the rib. The groove may be provided by any suitable method, such as machining, casting or deformation.

The first casing may be an inner casing, and the second casing may be an outer casing. Alternatively, the first casing may be an outer casing, and the second casing may be an inner casing.

Also disclosed is a method of manufacturing a heat exchanger core, the method comprising: providing a first casing; disposing a rib on an inner surface of the first casing; providing a second casing; contacting the rib and the second casing by inserting the first casing into the second casing; disposing a top head on an upper end of each of the first casing and the second casing; disposing a bottom head on a lower end of each of the first casing and the second casing; disposing an inlet on the first casing, the second casing, or combination thereof; and disposing an outlet on the first casing, the second casing, or combination thereof to manufacture the heat exchanger core, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet.

In an embodiment, the rib has a bar shape, and as shown in FIG. 12, preferably comprises a bend. When the first casing is inserted, e.g., forcibly inserted, into the second casing, the rib may be deformed so that a tip of the rib contacts and forms a seal, e.g., an interference fit, with the second casing.

Also disclosed is a method of manufacturing a heat exchanger, the method comprising: providing a shell; disposing a pressure vessel bottom head on the shell; disposing the heat exchanger core in the shell; and disposing a pressure vessel top head on the shell to manufacture the heat exchanger, wherein the pressure vessel top head, the pressure vessel bottom head, the shell, or a combination thereof, comprises a pressure vessel inlet, and wherein the pressure vessel top head, the pressure vessel bottom head, the shell, or a combination thereof comprises a pressure vessel outlet.

Also disclosed is a method of transferring heat between a first fluid and a second fluid, the method comprising: providing the heat exchanger; directing a first fluid into the pressure vessel inlet; and directing a second fluid into the inlet of the heat exchanger core to exchange heat between the first fluid and the second fluid.

The invention has been described with reference to the accompanying drawings, in which various embodiments are shown. This invention may, however, be embodied in many different forms, and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like reference numerals refer to like elements throughout.

It will be understood that when an element is referred to as being “on” another element, it can be directly on the other element or intervening elements may be present therebetween. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present. Also, the element may be on an outer surface or on an inner surface of the other element, and thus “on” may be inclusive of “in” and “on.”

It will be understood that, although the terms “first,” “second,” “third,” etc. may be used herein to describe various elements, components, regions, layers, and/or sections, these elements, components, regions, layers, and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or section from another element, component, region, layer or section. Thus, “a first element,” “component,” “region,” “layer,” or “section” discussed below could be termed a second element, component, region, layer, or section without departing from the teachings herein.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms, including “at least one,” unless the content clearly indicates otherwise. “Or” means “and/or.” As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. It will be further understood that the terms “comprises” and/or “comprising,” or “includes,” and/or “including” when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof.

Furthermore, relative terms, such as “lower” or “bottom” and “upper” or “top,” may be used herein to describe one element's relationship to another element as illustrated in the Figures. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. For example, if the device in one of the figures is turned over, elements described as being on the “lower” side of other elements would then be oriented on “upper” sides of the other elements. The exemplary term “lower,” can therefore, encompasses both an orientation of “lower” and “upper,” depending on the particular orientation of the figure. Similarly, if the device in one of the figures is turned over, elements described as “below” or “beneath” other elements would then be oriented “above” the other elements. The exemplary terms “below” or “beneath” can, therefore, encompass both an orientation of above and below.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

Exemplary embodiments are described herein with reference to cross section illustrations that are schematic illustrations of idealized embodiments. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments described herein should not be construed as limited to the particular shapes of regions as illustrated herein but are to include deviations in shapes that result, for example, from manufacturing. For example, a region illustrated or described as flat may, typically, have rough and/or nonlinear features. Moreover, sharp angles that are illustrated may be rounded. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the precise shape of a region and are not intended to limit the scope of the present claims. 

What is claimed is:
 1. A tubeless heat exchanger for heating a production fluid disposed in a vessel, comprising: a tubeless heat exchanger core disposed at least partially within the vessel, the tubeless heat exchanger core comprising an inner casing and an outer casing disposed around the inner casing, the inner and outer casings defining therebetween a flow passage for a thermal transfer fluid to flow, the tubeless heat exchanger core further comprising a core inlet arranged to receive the thermal transfer fluid and a core outlet arranged to provide the thermal transfer fluid, the core inlet and core outlet being fluidically connected to the flow passage, and at least one of the core inlet and core outlet being disposed on the inner casing; wherein each of the outer casing and the inner casing has an inner surface and an outer surface, wherein the respective inner surfaces face each other and define therebetween the flow passage for the thermal transfer fluid to flow and wherein at least a portion of the respective outer surfaces are arranged to be contacted by the production fluid, wherein the flow passage defines a path comprising at least one pass around a perimeter of the heat exchanger core; and wherein, in use, the thermal transfer fluid in the heat exchanger core transfers heat from the thermal transfer fluid to the production fluid through at least a portion of both the inner and outer casings.
 2. The heat exchanger of claim 1, further comprising: an outlet member, which penetrates the vessel and which fluidically connects the core outlet through the vessel to provide the thermal transfer fluid outside of the vessel; and a conduit fluidically connected to the heat exchanger core, and arranged to provide the thermal transfer fluid to the heat exchanger core, the conduit having a conduit outlet end fluidically connected to the core inlet and a conduit inlet end arranged to receive the thermal transfer fluid.
 3. The heat exchanger of claim 1, wherein the flow passage comprises a flow passage guide, the flow passage guide comprising at least one of: a rib, a ridge, and a deformation of the inner surface of one or both of the inner casing and the outer casing, to guide the flow of the thermal transfer fluid along the flow passage from the core inlet to the core outlet.
 4. The heat exchanger of claim 1, wherein the flow passage defines a helical path between the core inlet and core outlet.
 5. The heat exchanger of claim 1, wherein an entirety of the outer surfaces of the tubeless heat exchanger core is contacted by the production fluid.
 6. The heat exchanger of claim 1, wherein the inner casing and the outer casing of the heat exchanger core each have a largest outer diameter of 30 cm to 350 cm and a maximum height of 15 cm to 1,400 cm.
 7. The heat exchanger of claim 1, wherein an aspect ratio of the flow passage of the tubeless heat exchanger core is 10 to 100, wherein the aspect ratio is a ratio of a height of the flow passage to a width of the flow passage.
 8. The heat exchanger of claim 1, wherein at least one of the inner casing and the outer casing of the tubeless heat exchanger core has a thickness of 0.5 centimeters to 5 centimeters.
 9. The heat exchanger of claim 1, wherein the inner casing is coaxial with the outer casing.
 10. The heat exchanger of claim 1, wherein the production fluid contacts an entirety of the outer surfaces of the inner and outer casings of the heat exchanger core, and the production fluid, and the thermal transfer fluid each independently comprise a liquid, a gas, or a combination thereof.
 11. The heat exchanger of claim 1, wherein the production fluid and the thermal transfer fluid each independently comprise water, a substituted or unsubstituted C1 to C30 hydrocarbon, air, carbon dioxide, carbon monoxide, or a combination thereof.
 12. The heat exchanger of claim 1, wherein the production fluid comprises liquid water, steam, a thermal fluid, a glycol, or a combination thereof.
 13. The heat exchanger of claim 1, wherein the thermal transfer fluid does not contact the vessel.
 14. The heat exchanger of claim 1, wherein the flow passage is contained entirely within the vessel.
 15. The heat exchanger of claim 1, wherein the heat exchanger core comprises a core top head and a core bottom head, and wherein the inner casing and outer casing are disposed between the core top head and the core bottom head.
 16. The heat exchanger of claim 15, wherein the outer surfaces of the inner casing, the outer casing, and the bottom head are contacted by the production fluid.
 17. The heat exchanger of claim 16, wherein the outer surface of the top head is contacted by the production fluid.
 18. The heat exchanger of claim 1, wherein the inner casing and outer casing are both cylindrical.
 19. The heat exchanger of claim 1, wherein at least a portion of the conduit is coaxial with the tubeless heat exchanger core.
 20. The heat exchanger of claim 1, wherein the core inlet is disposed on the inner casing.
 21. The heat exchanger of claim 2, wherein the conduit is configured to provide the thermal transfer fluid from the conduit inlet, along the conduit to the conduit outlet and the core inlet to the flow passage, and wherein the conduit comprises a conduit outer surface, at least a portion of the conduit outer surface also arranged to be contacted by the production fluid.
 22. The heat exchanger of claim 1, wherein the outlet member mechanically attaches the core outlet to the vessel to provide mechanical support for the heat exchanger core and to avoid thermal stresses in the heat exchanger core within the vessel.
 23. The heat exchanger of claim 1, wherein the vessel has a vessel inlet arranged to receive production fluid and a vessel outlet arranged to provide heated production fluid.
 24. The heat exchanger of claim 1, wherein a vessel comprises a pressure vessel.
 25. The heat exchanger of claim 1, wherein the inner casing and the outer casing each independently have a circular cross-sectional shape, an elliptical cross-sectional shape, an oval cross-sectional shape, a stadium cross-sectional shape, a semicircular cross-sectional shape, a square cross-sectional shape, a rectangular cross-sectional shape, a triangular cross-sectional shape, or combination thereof.
 26. The heat exchanger of claim 1, wherein the inner casing and the outer casing have a same cross-sectional shape.
 27. The heat exchanger of claim 1, wherein the flow passage has a helical shape, a stepped shape, a shape of a segment of a circle, a shape of a segment of a helix, or a combination thereof.
 28. The heat exchanger of claim 1, wherein the flow passage has a circular cross-sectional shape, an annular cross-sectional shape, an elliptical cross-sectional shape, an oval cross-sectional shape, a stadium cross-sectional shape, a semicircular cross-sectional shape, a square cross-sectional shape, a rectangular cross-sectional shape, a triangular cross-sectional shape, or combination thereof.
 29. The heat exchanger of claim 3, wherein the flow passage guide is rigidly attached to the inner casing, the outer casing, or a combination thereof.
 30. The heat exchanger of claim 3, wherein the inner casing and the flow passage guide, the outer casing and the flow passage guide, or a combination thereof are rigidly attached by a weld.
 31. The heat exchanger of claim 3, wherein a pitch of the flow passage guide is between 0 degrees and 90 degrees with respect to a tangent direction, wherein the tangent direction is perpendicular to a longitudinal axis of the outer casing.
 32. A tubeless heat exchanger for heating a production fluid disposed in a vessel, comprising: a tubeless heat exchanger core disposed at least partially within the vessel, the tubeless heat exchanger core comprising an inner casing and an outer casing disposed around the inner casing, the inner and outer casings defining therebetween a flow passage for a thermal transfer fluid to flow, the tubeless heat exchanger core further comprising a core inlet arranged to receive the thermal transfer fluid and a core outlet arranged to provide the thermal transfer fluid, the core inlet and core outlet being fluidically connected to the flow passage, and at least one of the core inlet and core outlet being disposed on the inner casing; wherein each of the outer casing and the inner casing has an inner surface and an outer surface, wherein the respective inner surfaces face each other and define therebetween the flow passage for the thermal transfer fluid to flow and wherein an entirety of the respective outer surfaces are arranged to be contacted by the production fluid in the vessel, wherein the flow passage defines a path comprising at least one pass around a perimeter of the heat exchanger core; and wherein, in use, the thermal transfer fluid in the heat exchanger core transfers heat from the thermal transfer fluid to the production fluid through an entirety of both the inner and outer casings.
 33. The heat exchanger of claim 32, wherein the core inlet is disposed on the inner casing.
 34. The heat exchanger of claim 32, wherein the heat exchanger core is arranged within the vessel to avoid thermal stress in the heat exchanger core.
 35. The heat exchanger of claim 32, further comprising a conduit fluidically connected to the heat exchanger core, and arranged to provide the thermal transfer fluid to the heat exchanger core, the conduit having a conduit outlet end fluidically connected to the core inlet and a conduit inlet end arranged to receive the thermal transfer fluid.
 36. The heat exchanger of claim 35, wherein the conduit is configured to provide the thermal transfer fluid from the conduit inlet, along the conduit to the conduit outlet and the core inlet to the flow passage, and wherein the conduit comprises a conduit outer surface, at least a portion of the conduit outer surface also arranged to be contacted by the production fluid.
 37. The heat exchanger of claim 32, wherein the flow passage comprises a flow passage guide, the flow passage guide comprising at least one of: a rib, a ridge, and a deformation of the inner surface of one or both of the inner and outer casing, to guide the flow of the thermal transfer fluid along the flow passage from the core inlet to the core outlet.
 38. A tubeless heat exchanger for heating a production fluid disposed in a vessel, comprising: a tubeless heat exchanger core disposed at least partially within the vessel, the tubeless heat exchanger core comprising an inner casing and an outer casing disposed around the inner casing, the inner and outer casings defining therebetween a flow passage for a thermal transfer fluid to flow, the tubeless heat exchanger core further comprising a core inlet arranged to receive the thermal transfer fluid and a core outlet arranged to provide the thermal transfer fluid, the core inlet and core outlet being fluidically connected to the flow passage, and at least one of the core inlet and core outlet being disposed on the inner casing; wherein each of the outer casing and the inner casing has an inner surface and an outer surface, wherein the respective inner surfaces face each other and define therebetween the flow passage for the thermal transfer fluid to flow and wherein at least a portion of the respective outer surfaces are arranged to be contacted by the production fluid, wherein the flow passage defines a helical path between the core inlet and core outlet, wherein, in use, the thermal transfer fluid in the heat exchanger core transfers heat from the thermal transfer fluid to the production fluid through at least a portion of both the inner and outer casings; and wherein the flow passage comprises at least one of: a rib, a ridge, and a deformation of the inner surface of one or both of the inner casing and the outer casing, to guide the flow of the thermal transfer fluid along the flow passage from the core inlet to the core outlet.
 39. The heat exchanger of claim 38, wherein an aspect ratio of the flow passage of the tubeless heat exchanger core is 10 to 100, wherein the aspect ratio is a ratio of a height of the flow passage to a width of the flow passage.
 40. The heat exchanger of claim 38, wherein the core inlet is disposed on the inner casing.
 41. The heat exchanger of claim 38, wherein the heat exchanger core is arranged within the vessel to avoid thermal stress in the heat exchanger core. 